Deckelmann, P. and Dietrich, T., "Powertrain Testing - New Generation Injection Valves in Laboratory and Production," SAE Technical Paper 2016-01-2191, 2016, doi:10.4271/2016-01-2191.
This paper will focus on a powertrain injector application solution for R&D and production. PIA is a product for triggering and analyzing current and newly developed injection valves (both solenoid and piezoelectric). The article examines an important obstacle of injection testing, which is creating realistic environmental conditions for injectors. It shows how PIA realizes this through high-end ECU simulation for current and new generations, creating different operating conditions.Berghof Testing combined control, performance and measuring technology into PIA. The compact, intelligent and economical device can be integrated into all existing injector test systems. In addition to the standard version the application offers enhancements such as intelligent injections, injector calibration, polarity detection and image processing for spray analyses. This excludes evaluations based on erroneous fundamentals of the injection behavior to make sure injection can in fact get cleaner by improving fuel consumption and lowering emissions.Currently PIA is used by automotive Tier 1 suppliers to verify injection valves in laboratory environments. Tests include injector opening and closing times, spray pattern and flow volume at different triggering parameters. New generation ECUs utilize analysis functions, creating real life measurements, for autonomous trigger optimization. For future use of PIA these complex in-car functions can be simulated. The solution integrates future-oriented technologies like real-time operating systems, FPGA and automotive BUS systems (CAN, LIN, FlexRay). With PIA various procedures for laboratory based optimization can be realized and transferred into production.